Articles of composite structure having appearance of wood

ABSTRACT

A door or other entryway component of synthetic resin composite construction and closely resembling the appearance of stained real wood. Skin portions of doors and other structures have a surface layer of clear gel coat resin molded to include the texture of a wood grain surface. A subsurface layer adjacent the clear gel coat layer is of pigmented gel coat resin. A structural support layer of the skin is of reinforced resin. Skins of a door or similar article are mounted on frames, and dense micro porous resin foam is provided between the skins to form a solid structure such as a door. Moldings retaining glass panels in openings defined in the door or similar structure are attached to the skins by adhesively fastening the moldings to the skins. Fasteners mounted in the moldings so that there are no plugged holes in the exterior surfaces of the moldings are used to locate the moldings properly with respect to the skins by inserting the fasteners into predrilled holes in the skins. The assembled doors and other structures can be finished by staining and coating with a finish system such as a urethane varnish to provide an appearance closely resembling real wood.

RELATED APPLICATIONS

[0001] This application is a division of U.S. patent application Ser.No. 09/779,199, filed Feb. 7, 2001, now U.S. Patent No. ______.

BACKGROUND OF THE INVENTION

[0002] The present invention is related to articles of compositeconstruction including reinforced synthetic resins, and in particularrelates to such articles finished to resemble the appearance of realwood.

[0003] Real wood, finished by staining and provision of a protectivecoating such as natural or synthetic lacquer, varnish, or resinfinishes, has a pleasing appearance and a substantial and solid feel.Many species of wood having a desirable appearance, however, such asmost hardwoods, are expensive and require considerable amounts ofskilled labor and time for production of finished articles. Theappearance of wood with a bright finish, that is, a finish exposing thecolor and texture of the wood grain, is particularly desirable forexterior doors and entryway structures, although they may be quiteexpensive to construct of real wood.

[0004] While the appearance of wood is very pleasing for entryways andother exterior features of building, wood is susceptible to damagecaused by weather and insect pests, which can destroy the wood or damageits finish. Frequent and often costly maintenance is thus required toprevent rapid deterioration of the appearance of real wood with a brightfinish exposed to the weather.

[0005] As a more economical substitute, then, entryway doors andnumerous other products for which the appearance of wood is desirablehave recently been made of composite construction including outer layersof fiber-reinforced synthetic resins prepared to resemble wood. Theappearance of such previously available imitation wood products,however, has at best failed to match the attractiveness of well-madestructures of actual wood with a bright finish.

[0006] While some products of plastics and composite construction havebeen molded to include surface texture resembling the grain of wood, theappearance of depth that is so attractive in real wood has previouslynot been possible to reproduce in the finish of such articles. Forexample, Mrozinski U.S. Pat. No. 5,399,373 discloses production ofimitations of natural wood by molding a resin-based gel coat to includea surface shape closely copying the surface grain texture of real wood.For this layer Mrozinski teaches the use of a pigmented gel coatmaterial whose color is related to the color of the wood being imitated.Mrozinski's process also requires the use of artists' oil colors orsimilar pigments to fill the surface texture to imitate the appearanceof real wood. The use of such artists' oils, however, requiresconsiderable skill and time, and still results in an appearance somewhatlacking in realism.

[0007] Doors and other entryway components frequently include panelssurrounded and supported by moldings attached to larger frame members.Such panels, particularly glass panels of doors and entryway sidelights,have to be supported securely with respect to the surrounding frames.The weight of large multi-layered glass panels, particularly when theyinclude decorative panes assembled in metal caming, can be significant.Moldings used to attach such glass panels to frame structures musttherefore be held securely in the required locations on a door or otherframe structures.

[0008] While adhesives are the primary mechanism for interconnecting theparts of synthetic resin composite structures, fasteners extendingthrough the moldings have also been required in previously known doorsand other structures of composite construction in order to ensure thatheavy glass panels are held securely enough. The holes through themoldings where such fasteners have been installed have then had to beplugged and finished to match the surrounding surfaces of the moldings,requiring significant time and skill.

[0009] What is desired, then, is an improved composite constructionincluding synthetic resin surface portions that can be finished toprovide an attractive pleasing appearance closely resembling finishednatural wood, while avoiding the disadvantages of natural wood. It isalso desired to be able to secure moldings to the skins or othercomponents of a door or other structure of composite constructionwithout having to use fasteners that extend through the moldings totheir exterior surfaces.

SUMMARY OF THE INVENTION

[0010] The present invention provides an answer to the above-stated needfor a product of composite construction having an appearance closelyimitating real wood, by providing a structure for the exterior skin of aproduct of composite materials incorporating synthetic plastics thatwhen finished has the appearance of real wood, and by providing a methodfor making such products.

[0011] As first aspect of the invention, an article manufactured ofcomposite materials and having an appearance closely resembling realwood includes an outer layer of a transparent resin-based gel coatmaterial whose outer surface is molded to incorporate in detail thegrain shape of the surface of bare real wood. A subsurface layeradjacent to the surface layer of transparent gel coat material is ofpigmented resin-based gel coat material of a color related to orresembling the color of unfinished wood of the type whose surface shapeis represented. Beneath the subsurface layer is a structural supportinglayer which may be of a suitable synthetic resin, reinforced as by glassor other fibers.

[0012] When an appropriate finish, such as a wood stain and a protectivecoating such as laquer, varnish, urethane, or another suitable syntheticresin, is applied to the outer surface of the outer layer of clear gelcoat material, the resulting appearance of such a structure according tothe invention has a remarkable resemblance to real wood with a similarstain and protective finish. An article constructed according to theinvention and provided with such a finish presents an appearance ofdepth closely resembling the appearance of real wood with a similar typeof finish.

[0013] In one preferred embodiment of this aspect of the invention theouter layer of transparent gel coat is substantially completely clearand colorless.

[0014] In one preferred embodiment of this aspect of the invention theouter layer of transparent gel coat has an average thickness in therange of about 0.012 to 0.020 inch, while the subsurface layer ofpigmented gel resin has an average thickness in the range of about0.003-0.010 inch.

[0015] A second major aspect of the present invention is the method ofmanufacturing an article of composite structure by providing a firstskin sheet including an outer layer of transparent gel resin molded toincorporate a surface shape imitating the grain of real wood; providinga second skin sheet, fastening the skin sheets to opposite faces of aframe structure; filling the cavity defined between the skin sheets andwithin the frame structure with a structural synthetic resin foamadhering to the frame structure and the skin sheets; curing the resinfoam and thereby forming a substantially rigid core structureinterconnecting the skin sheets and frame; and applying a protectivefinish coating to the outer surface of the outer layer of at least thefirst skin sheet.

[0016] A third aspect of the present invention is the provision of anarticle of composite construction resembling an article of real wood andincluding fasteners fixedly mounted in moldings and used to locate themoldings precisely with respect to an article of composite constructionwithout the use of fasteners extending entirely through such moldings sothat unsightly plugs and difficult finish work are not needed.

[0017] The foregoing and other objectives, features, and advantages ofthe invention will be more readily understood upon consideration of thefollowing detailed description of the invention, taken in conjunctionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0018]FIG. 1 is an isometric view of a portion of a door of compositeconstruction according to the present invention.

[0019]FIG. 2 is a sectional elevational view of a portion of a mold usedto form a skin for an article such as the door shown in FIG. 1.

[0020]FIG. 3 is a view similar to that of FIG. 2 showing an outer layerof a transparent resin-based gel coat applied to the mold as part of theprocess of manufacturing a door skin.

[0021]FIG. 4 is a view similar to FIG. 3 also showing the addition of asubsurface layer of a pigmented resin-based transparent outer gel coatmaterial onto the transparent outer layer.

[0022]FIG. 5 is a view similar to FIG. 4 also showing the addition of alayer of reinforced resin to the previously present layers.

[0023]FIG. 6 is a sectional view of a portion of a door according to thepresent invention, taken in the direction indicated by line 6-6 in FIG.1, at an intermediate stage in the manufacture of such a door.

[0024]FIG. 7 is a view similar to FIG. 6 showing the portion of a doorat a subsequent stage of manufacture.

[0025]FIG. 8 is a sectional view of a door constructed according to theinvention.

[0026]FIG. 9 is a view similar to FIG. 8, showing a door according tothe invention and that has an opening extending through it for receivinga glazed panel.

[0027]FIG. 10 is a sectional detail view at an enlarged scale showing aportion of the door shown in FIG. 9, with moldings in place to securelymount a glazing panel within the opening.

[0028]FIG. 11 is a sectional detail view showing a portion of the doorshown in FIG. 1 and showing the layers of one system of stain andprotective finish coats.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Referring now to the drawings which form a part of the disclosureherein, shown in FIG. 1 is a corner portion of a door 12 of compositeconstruction according to the present invention. As shown along theright hand side of FIG. 1, the structure of the door 12 is cut away toreveal its interior construction in section view. A pair of door skinsheets 14 and 16 imitating real wood are located on opposite sides ofand are adhesively attached to a frame structure 17. The frame structure17 includes a bottom rail of which an interior structural portion 18 maybe of a multilayered laminated wood material. An outer surface piece 20is of solid real wood, preferably of the species imitated by the skinsheets 14 and 16. The frame structure 17 also includes a pair of uprightstiles, each preferably constructed similar to the bottom rail shown inFIG. 1, and a horizontal top rail, the stiles and rails forming arectangular peripheral shape.

[0030] The frame structure 17 has a pair of opposite substantiallyplanar opposite faces 22, and the skin sheets 14 and 16 are eachattached to a respective one of the faces 22 by a suitable adhesivecapable of permanently attaching the skins 14 and 16 to a woodensurface. For example, a suitable adhesive for attaching skin sheets 14and 16 of the construction described below is “Plastic Welder II,”available from ITW Devcon, of Danvers, Mass.

[0031] Between the skin sheets 14 and 16 and within the area surroundedby the frame structure 17 the entire space between the door skin sheets14 and 16 is filled to form a core 24. The material of the foam core 24is preferably a relatively dense microcellular urethane foam produced inplace from a two-part self-rising composition. The foam material of thecore 24 preferably adheres strongly to the interior surfaces of the skinsheets 14 and 16 and the stiles and rails of frame structure 17, andthus helps to bond the component structures of the door 12 to eachother.

[0032] The outer surface of the skin sheet 14 of the finished door 12has the appearance of real wood finished “bright” with a substantiallytransparent finish. Wood grain structures closely resembling thecorresponding structures in real wood are clearly apparent, as at 26 and28. Portions 26 simulate relatively open pore portions of the surface ofa piece of a hardwood such as, for example, oak, while portions 28represent the harder portions of natural wood grain structure. The skinsheet 16 is of substantially similar appearance, and imitates anopposite side of a door of the same real wood species.

[0033] The structure of each of the skin sheets 14 and 16 is critical tothe ability of the present invention to provide a door 12 or otherstructures with an attractive appearance closely resembling actual woodwith a “bright” finish.

[0034] According to the present invention a door skin sheet 16, or askin sheet for another article with a bright finished wood appearance,is manufactured by preparing a mold 30 to reproduce faithfully thedetails of the surface configuration of an actual wooden modelstructure. In preparing a door skin sheet 16, for example, an actualwooden door is manufactured, but its surface is left bare, and its grainstructure is made clearly apparent and accentuated by carefully sandingand wire brushing the wood surfaces. The surface of the wooden model isthen treated to prevent it from sticking to the material of which themold is to be made, as by spraying the wood surfaces with an appropriatemold release compound. From the model a mold is made of material capableof reproducing fine detail, such as a conventional silicone rubber moldmaterial using conventional mold preparation techniques. For example, anRTV silicone rubber compound available from Performance Silicones, Inc.,of Chino, Calif., under stock number PSI 651B is suitable. The moldfaithfully reproduces the minute surface irregularities of the woodgrain of the model. As shown in FIG. 2, a mold surface 32 of the mold 30thus includes irregularities such as the projections 34 corresponding toopen pores in the grain of the surfaces of the wood of the model, whilerelatively smooth portions 36 of the mold surface 32 correspond to theslightly protruding harder portions of the grain of the wood of themodel from which the mold 30 is made. Thus, the projections 34 in themold 30 are intended to produce grain pore portions such as those inshown at 26 in FIG. 1, and the smoother parts 36 of the mold 30 areintended to produce correspondingly smooth areas such as those shown at28 in FIG. 1.

[0035] It is of critical importance according to the present inventionto produce a surface shape of an article such as a skin sheet 14corresponding closely with the surface of the piece of wood to beimitated. The surface shape alone, however, is insufficient to obtainthe desired appearance in the final product, as will be explainedpresently.

[0036] Referring next to FIG. 3, a skin sheet 14 or 16 is prepared bybuilding up a succession of layers of material in the mold 30. Afterapplying a suitable mold release compound (not shown) to the moldsurface, a first, or outer layer 40 is applied to the mold surface 32,to an average thickness 42 of, preferably, about 0.018 inch, although athickness as small as about 0.012 inch or as great as 0.020 inch wouldalso be satisfactory. The outer layer 40 is of a transparent, preferablycompletely clear and colorless, resin-based gel coat material, althougha slight coloration is acceptable, so long as the outer layer 40 remainsessentially transparent. A preferred material for the outer layer 40 isa clear UV-curing unpromoted, polyester-based gel coat materialavailable from NESTE Polyesters, Inc. of Ft. Smith, Ark., under thetrademark NESTE MAXGUARD and designated as SL00221B, version #6. Such agel coat material may be applied to the mold surfaces 32 to the requiredthickness in uncured form by conventional spray application, and is thencured, leaving a relatively smooth and regular inner surface 44 of theouter layer 40. The preferred material includes fillers and UV resistantcomponents, but is flexible enough to withstand removal of the skinsheet 14 or 16 from the mold 30 without cracking.

[0037] When the outer layer 40 has been cured according to themanufacturer's instructions, a subsurface layer 48 of pigmented gel coatmaterial is applied to it and cured as it remains in the mold 30, in athin but complete coat having a thickness 50 preferably sufficient forthe subsurface layer 48 to be substantially opaque and to appear solidlycolored as viewed through the outer layer 40.

[0038] Preferably, the subsurface layer 48 is a polyester-based gel coatmaterial with a uniform pigmentation similar in color to the lightestcolor present in the species of wood intended to be imitated by the skinsheet being prepared. As an example, using NESTE MAXGUARD base color gelcoat material in a thickness 50 of at least about 0.003 and preferablyabout 0.005-0.010 inch provides the needed opacity and definite color tobe visible with an appearance of depth beneath the outer surface 44 ofthe outer layer 40. For an imitation of mahogany a soft salmon colorpigment such as that available as NESTE's Mahogany gel coat NG32626,version #4, provides a good result, while for imitating oak a pinkishtan color such as NESTE's Pink Rose gel coat RG31515, Version #3, issatisfactory.

[0039] The combination of the textured transparent outer layer 40 andthe pigmented subsurface layer 48 result in the desired appearance ofthe finished skin sheet 14 according to the invention once the outerlayer 40 has been stained and provided with a protective coatingmaterial, as will be described subsequently.

[0040] Once the subsurface layer 48 has been cured, a structural supportlayer 54 is applied to adhere to the subsurface layer 48 to providestructural support for both the outer gel coat layer 40 and thesubsurface gel coat layer 48. The structural support layer 54 may be,for example, of a conventional resin with embedded glass fibers. Forexample, a 3-ounce matt of glass fiber strands such as a VETROTEXCERTAINTEED continuous filament glass fiber matt impregnated with an AOCultraviolet curing polyester resin layer may be applied to adhereclosely to the exposed inner surface of the subsurface layer 48. Apreferred resin for the structural support layer 54 is an ultravioletcured polyester resin RX1270 available from Alpha Owens Company ofPerris, Calif. In small spaces and corners of small radius, a suitablepolyester-based adhesive putty such as “PolyBond B38,” available fromA.T.C. Chemical, Inc., of Buffalo, N.Y., is used to avoid air pocketsbetween the subsurface gel coat layer 48 and the glass-reinforced resinof the structural support layer 54. The fiber-reinforced structuralsupport layer 54 is then cured to complete the skin sheet 16.Preferably, the cured structural support layer 54 has a thickness 56 ofabout 70 mils, to make the overall thickness 58 of the skin sheet 16 ofthe door 12 equal about {fraction (3/32)} inch, although other articlesmay require different thicknesses.

[0041] A pair of skin sheets 14 and 16 prepared as just described arepreferably kept in their respective molds 30, and an appropriateadhesive material such as the previously mentioned “Plastic Welder II”is applied to appropriate portions of the surface of each structuralsupport layer 54. The two molds 30 containing and supporting the skins14 and 16 are then placed in properly registered locations to adhere tothe frame structure 17, as shown in FIG. 6, with each mold 30 adequatelysupported and pressed toward the frame structure 17 by a rigid caul (notshown).

[0042] The skin sheets 14 and 16, together with the frame structure 17,define a cavity 60, into which an appropriate quantity of a self-foamingresin mixture is placed. The molds 30 are supported adequately to resistthe force generated while the foam material expands to form a foam core24 fully filling the cavity 60 and adhering to the exposed surfaces ofthe structural frame 17 and the structural support layer 54 of each ofthe skin sheets 14 and 16. The foam is formed in place by pumping in theappropriate quantity of freshly mixed foam forming compound after theskin sheets 14 and 16 have been attached to the structural frame. Thepreferred core density of 28 lbs/ft³ when expanded to fill the spacewithin the shell of the door 12 is slightly less than that of real wood.The resin foam solidifies to form a substantially rigid microcellularfoam core 24, shown in FIGS. 1 and 7.

[0043] After the foam core 24 has solidified and no longer urges theskin sheets 14 and 16 outwardly apart from each other, the molds 30 maybe removed from the skin sheets 14 and 16. The skin sheets 14 and 16 canthen be trimmed to the proper finished dimension flush with the surfacepiece 20 of each of the stiles and rails of the structural frame 17. Asshown in FIG. 8, the resulting door 12 includes a pair of skin sheets 14and 16, the structural frame 17, and the foam core 24, all of which areadhesively unified into a rigid structure having the weight and afeeling of solidity similar to that of a real wooden door of comparablesize.

[0044] Referring to FIGS. 9 and 10, for a door 80 similar to the door12, but in which it is desired to have a glass panel, the door isprepared generally according to the same method set forth with respectto the door 12, except that the skin sheets 82, 84 include lips orflanges 86, 88 surrounding an area where a panel is to be placed anddirected inwardly toward each other to exclude the foam from where thepanel is to be placed. Once the molds have been removed from the door80, and in conjunciton with trimming the door skin sheets and surfacepieces of the structural frame, a suitable opening 90 is cut through thedoor 80 to receive the intended glass panel 92 or the like, and a set offastener receiving holes 94 are drilled in predetermined locationsadjacent to the opening 90 defined in the door 80 and surrounded by theflanges 86 and 88. Suitable locations of the fastener receiving holes 94are shown in FIG. 10, for example.

[0045] A pair of moldings 100 are prepared using the same method used toprepare the skin sheets 14, 16, 82, and 84, so that the exteriorsurfaces of the moldings 100 also include the wood grain shape detailsin an outer layer 40 of transparent gel coat material beneath which is asubsurface layer 48 of pigmented gel coat material, and beneath which isa structural support layer 102. The structural support layer 102 may besubstantially thicker than the structural support layer 54 of a skinsheet, since the molding is likely to be subjected to substantiallygreater and more concentrated stresses, as a result of its function insupporting a heavy glass panel 92. The glass panel 92 has a substantialweight, since it is triple-glazed and includes not only inner and outersmooth panes 104 of full size, but metal caming 105 supporting multiplepieces of decorative glass, with a total thickness 106 which may be, forexample, 1 inch.

[0046] Each of the moldings 100 also is provided with a foam core 108,which may be machined to fit against the skin sheet 82 or 84 and theflange 86 or 88, as shown in FIG. 10. In conjunction with shaping thefoam core 108, sockets are machined and self-locking fasteners 110 to bereceived in the fastener receiving holes 94 are mounted in predeterminedlocations in the moldings 100. The locations of the fasteners 110 arepreferably established in the moldings 100 with the moldings 100 held ina suitable jig, and the fasteners 110 are then set precisely in an epoxyor other suitable adhesive 111 so that each fastener 110 is rigidly andsecurely fastened to the structural support layer 102 of the molding100.

[0047] The self-locking fasteners are capable of being received inappropriate holes and thereafter securely resisting withdrawal. They donot require rotation during insertion, so there is no need for a holeextending through to the outside of the molding 100. A suitableself-locking fastener is of a molded synthetic plastic resin and isavailable from Aveco, of Detroit, Mich., as its number AVI4036 fastener.

[0048] One molding 100 may be placed into the required position inregistration with the opening and the flange 88 in the skin sheet 84 onone side of the door 80 after applying a quantity of an adhesivematerial to the skin sheet 84. When the molding 100 is pushed toward theskin sheet 84 the self-locking fasteners 110 associated with thatmolding are also pushed into the fastener receiving holes 94 in the skinsheet 84. The fasteners thus securely establish the position of themolding 100 with respect to the door 80, particularly during the timewhile the adhesive material cures. With one molding 100 in place in thedoor 80, the glass panel 104 can be placed properly with respect to thefirst molding 100, after which the other skin sheet 82 is provided withan appropriate layer of adhesive material and the second molding 100 isplaced against the opposite side of the door 80 and pushed into place sothat its fasteners 110 enter the fastener receiving holes 94 in the skinsheet 82 locking that molding 100 into the required position withrespect to the door 80.

[0049] Referring to FIG. 11, once the skin sheets 14 and 16 and, to theextent necessary, the surface pieces 20 of the frame structure 17 of thedoor 12 or the corresponding portions of the door 80 have all beentrimmed to the required size, and moldings 100 have been installed, theentire door 12 or 80 can be provided with a protective, preferably clearand transparent, finish 118. This is accomplished by application of astain such as a wood stain applied in a conventional manner to fill thegrain pores 26 and, to a lesser extent, to cover and color the portions28 representing the hard part of the wood grain represented by each skinsheet or molding. As when staining a real wood surface, it may bepreferable to use a stain system installed in two coats, first applyinga filler coat 120 to fill the pore portions 26. For example,Sherwin-Williams grain filler in the appropriate color for the woodbeing imitated, available from the Sherwin-Williams Co. of Cleveland,Ohio, may be used. Thereafter, a second, thinner, layer 122 of stain isapplied in generally the same manner used in staining real wood of thesame type. For the stain coat 122, Sherwin-Williams oil-based stain isused in the appropriate color to match the grain filler 120. Once thestain has been applied in the usual fashion, a durable protective finishcoating such as laquer, varnish, or a synthetic resin finish is appliedin much the same manner as in finishing wood, to coat the stainprotectively with a hard, scratch-resistant, transparent surface coathaving the desired glossy, matte, or satin surface texture. For example,two coats 124 and 126 of an acrylic urethane sealer coating such asSherwin-Williams Acry Glo Base Clear are applied followed by two coats128 and 130 of a clear acrylic finish coat such as Sherwin-WilliamsAcrylic Top Coat.

[0050] The combination of the transparent outer layer 40, with itsthickness 42, and the pigmented subsurface layer 48, give an appearanceof a certain depth, so that with stain on the textured outer surface ofthe outer layer 40 and the protective finish coatings over the layer 122of stain the resulting appearance closely resembles that of a real woodsurface that has been stained and coated with a similar laquer, varnish,or synthetic finish material.

[0051] The terms and expressions which have been employed in theforegoing specification are used therein as terms of description and notof limitation, and there is no intention, in the use of such terms andexpressions, of excluding equivalents of the features shown anddescribed or portions thereof, it being recognized that the scope of theinvention is defined and limited only by the claims which follow.

1. A method for manufacturing an article of composite construction withat least part of the article having an appearance imitating naturalwood, the method comprising: (a) providing a first skin sheet includinga transparent outer gel coat layer having an outer surface molded toimitate a wood grain, a subsurface pigmented gel coat layer and areinforced synthetic resin structural support layer; (b) providing asecond skin sheet; (c) providing a frame structure for said article; (d)fastening said first and second skin sheets to said frame structure,thereby defining a cavity between said first and second skin sheets andsurrounded by said frame structure; (e) filling said cavity with astructural resin foam adhering to said frame structure and said firstand second skin sheets; (f) curing said structural resin foam, therebyforming a substantially rigid core structure adhered to said framestructure and to said first and second skin sheets; and (g) thereafterapplying a protective finish to said outer surface of said first skin.2. The method of claim 1, including the step of applying a stain to saidouter surface of said transparent outer gel coat layer of said firstskin sheet to provide a desired finish color to said first skin sheetprior to applying said protective finish coat thereto.
 3. The method ofclaim 1, including the further step of supporting and pressing saidfirst and second skin sheets against said structural frame inpredetermined positions while said structural foam cures.
 4. A method ofproducing an article of composite construction having an appearanceclosely imitating real wood, comprising: (a) preparing a mold includinga mold surface configuration closely resembling a surface of a woodenarticle to be imitated by said article of composite resin construction;(b) forming an outer layer of a transparent gel coat material applied tosaid mold surface to produce an image of said surface of said woodenarticle as an outer surface of said article of composite construction;(c) forming a subsurface layer of a pigmented second gel coat materialadhering to said outer layer while said outer surface remains on saidmold surface; (d) allowing said outer layer and said subsurface layer tocure; (e) thereafter, applying a layer of uncured fiber-reinforced resinto said subsurface layer of pigmented resin and causing saidfiber-reinforced resin to cure, as a structural support for said surfacelayer and said subsurface layer, thereby forming a skin member; (f)applying a stain of a color selected to resemble a selected species ofwood to an outer surface of said outer layer; and (g) providing aprotective finish over said outer surface and said stain.
 5. The methodof claim 4, including the further step of incorporating said skin memberin a composite product structure.
 6. The method of claim 4 wherein saidprotective finish is transparent.
 7. The method of claim 4 wherein saidouter surface layer has a predetermined thickness.
 8. The method ofclaim 4 wherein said subsurface layer has a predetermined thickness. 9.A method for manufacturing an article of composite construction,comprising: (a) forming a main component of an article of compositesynthetic resin construction; (b) defining an opening extending throughsaid main component in position to receive a panel; (c) defining afastener receiving hole through an exterior skin of said main componentin a predetermined location with respect to said opening; (d) providinga panel-retaining molding; (e) mounting an elongate fastener securely insaid molding in a predetermined location with said fastener extendingfrom a mating face side of said molding; (f) placing a panel within saidopening through said main component of said article; and (g) placingsaid molding into a required position against said skin and said panel,with said elongate fastener extending into and securely engaging saidfastener receiving hole and thereby retaining said molding in saidrequired position with respect to said skin and said panel.
 10. Themethod of claim 9 wherein said panel retaining molding is of compositeconstruction.